US20060113967A1 - Saturation control of electric machine - Google Patents
Saturation control of electric machine Download PDFInfo
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- US20060113967A1 US20060113967A1 US10/996,411 US99641104A US2006113967A1 US 20060113967 A1 US20060113967 A1 US 20060113967A1 US 99641104 A US99641104 A US 99641104A US 2006113967 A1 US2006113967 A1 US 2006113967A1
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- winding
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- magnetic circuit
- rotor
- alternator
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P31/00—Arrangements for regulating or controlling electric motors not provided for in groups H02P1/00 - H02P5/00, H02P7/00 or H02P21/00 - H02P29/00
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
- H02K21/02—Details
- H02K21/04—Windings on magnets for additional excitation ; Windings and magnets for additional excitation
- H02K21/046—Windings on magnets for additional excitation ; Windings and magnets for additional excitation with rotating permanent magnets and stationary field winding
Definitions
- the invention relates to electric machines such as alternators and motors, and in particular to the control of such machines.
- a typical permanent magnet (PM) alternator or motor has a rotor 102 supporting permanent magnets 104 and mounted on a rotatable shaft 108 .
- a stator 110 has a plurality of windings 112 between a plurality of teeth 114 mounted to a back iron 116 . (For ease of illustration, the adjacent elements of windings 112 in FIG. 1 are shown unconnected.)
- an external torque source forces rotation of the shaft, and the interaction of the magnets and the windings causes a magnetic flux to loop the windings in the slots.
- PM machines can have an “inside rotor” configuration as shown In FIG. 1 , or an “outside rotor” configuration (not shown).
- the present invention provides an electric alternator/motor comprising: a rotor having a plurality of permanent magnets; a stator having a plurality first slots and a plurality of second slots, the first slots being located on a periphery of the stator opposing the rotor, the second slots being located on an opposite side of the first slots relative to the rotor; at least a first winding disposed in a plurality of said first and second slots; at least a first magnetic circuit defined in the stator and rotor which encircles at least one first slot in which the first winding is disposed; at least a second magnetic circuit encircling at least one of the second slots in which the first winding is disposed, the second magnetic circuit sharing a common portion of the stator with the first magnetic circuit, the second magnetic circuit including a magnetically saturable portion of the stator distinct from the common portion; at least a second winding disposed adjacent the first winding in a plurality of second slots; a third magnetic circuit defined in the stator stator
- the invention provides a machine operable as at least one of an electric alternator/generator and an electric motor, the machine comprising a rotor and stator assembly, the assembly having a stator including at least a first winding, the assembly also having first and second magnetic circuits and a saturation control assembly, the first magnetic circuit including the rotor and encircling at least a first portion of the first winding, the second magnetic circuit encircling at least a second portion of the first winding remote from the first magnetic circuit, the first and second magnetic circuits magnetically coupled when current flows in the first winding, the second magnetic circuit including a portion which is magnetically saturable, the saturation control assembly being operatively associated with the magnetically saturable portion of the second circuit and operable to controllably vary a saturation level of said saturable portion.
- the invention provides an electric alternator comprising: a magnetic rotor; a stator having a body and at least one power winding adapted to generate voltage and current at least partially in response to rotor movement relative to the stator, the stator further comprising at least one saturable core inductor assembly in series with the power winding, wherein a saturable core portion of the saturable core inductor assembly is intrinsically provided by the stator body; and a saturation control apparatus adapted to selectively control a saturation level of the saturable core portions.
- the invention provides an electric machine operable as at least one of an electric alternator/generator and an electric motor, the machine having a rotor and a stator, the stator including at least a first winding, the machine comprising: a first magnetic circuit which includes the rotor and encircles at least a first portion of the first winding; a second magnetic circuit which encircles at least a second portion of the first winding, the first and second magnetic circuits magnetically coupled when current flows in the first winding, the second magnetic circuit including a portion which is magnetically saturable; and means for controllably varying a saturation level of said saturable portion.
- the invention provides a method of regulating an electrical output connected to a load, the method involving at least one alternator connected to the load, the alternator having a magnetic rotor, a stator and at least one stator winding, the winding associated with a primary magnetic circuit including the rotor and a secondary magnetic circuit defined in the stator, the secondary magnetic circuit being magnetically coupled to the primary magnetic circuit and including a magnetically saturable portion, the method comprising the steps of moving the rotor relative to the stator to generate an output current in the winding, and controllably varying a saturation level of a portion of the secondary magnetic circuit.
- the invention provides a method of power sharing among such machines. Still other inventions are disclosed in this specification and attached figures, as well, and the present application claims all such inventions.
- FIG. 1 is a somewhat schematic cross-sectional view of a prior art permanent magnet alternator/motor
- FIG. 2 is somewhat schematic partial cross-sectional view of a alternator/motor according to the present invention
- FIG. 3 is a schematic of a partial equivalent circuit of the alternator/motor of FIG. 2 , illustrating its functional aspects;
- FIG. 4 is similar to FIG. 2 , but depicting another embodiment of the invention.
- FIG. 5 is a block diagram schematically illustrating another aspect of the present invention.
- FIG. 6 is a block diagram schematically illustrating another aspect of the present invention.
- Alternator/motor 10 has a rotor 12 with permanent magnets 14 which is mounted for rotation relative to a stator 20 .
- Stator 20 has at least one power winding 22 and preferably at least one control winding 24
- this embodiment stator 20 has a 3-phase design with three electromagnetically-independent power windings 22 (the phases are denoted by the circled numerals 1, 2, 3, respectively) and, correspondingly, three independent control windings 24 .
- the power and control windings are separated in this embodiment by a winding air gap 26 and disposed in radial slots 28 between a plurality of adjacent teeth 30 . (For ease of illustration in FIG. 2 , the adjacent elements of control winding 24 are shown unconnected.
- the materials for PM machine 10 may be any deemed suitable by the designer. Materials preferred by the inventor are: samarium cobalt permanent magnets, copper power and control windings, a suitable saturable electromagnetic material for the stator teeth such as electrical silicon steels commonly used in the construction of magnetic machines, power and control flux busses.
- the stator teeth, power and control flux busses may be integral or non-integral with one another, as desired.
- the designer will select the rotor and stator dimensions and materials based at least in part on the desired properties of the magnetic circuits (described below) in the machine to yield the desired machine performance, etc.
- the control flux bus 32 is magnetically saturable, as will be described below.
- Power winding 22 in this embodiment consists of a single conductor which enters slot 28 on a first side of power flux bus 36 , crosses power flux bus 36 at the other end and exits slot 28 on the second or other side of power flux bus 36 (i.e. opposite to the first side, or side of entry) and proceeds to a next slot 28 of the same phase, where the power winding 22 preferably enters this next slot from the second side of power flux bus 36 instead of the first side, as described above.
- the winding of power winding 22 is preferably similar to that described in the incorporated reference.
- control winding 24 is wrapped around the control flux bus, in this embodiment preferably multiple times, such as 25 times, for reasons described below.
- the direction of winding between adjacent appropriate slots i.e. appropriate to maintain phase correspondence with the power winding
- Control winding 24 is connected to a current source and control system 50 (see FIG. 3 ), which in this example includes a variable current DC source and an appropriate solid state control system preferably having functionality as described further below.
- the current provided by such source is preferably sufficient to saturate control bus 32 , as will be described.
- alternator/motor 10 as just described can also be represented schematically by an equivalent circuit 10 ′ having a plurality of alternating current sources 12 ′ (i.e. each, equivalent to the moving magnetic rotor system in conjunction with the portion of a power winding 22 located in slot portions 28 a ) connected to a plurality of power inductors 22 ′ (i.e. equivalent to the portion of the primary winding 22 located in the slot portion 28 b ), the current sources 12 ′ and power inductors 22 ′ arranged alternately in series.
- Associated with power inductors 22 ′ are a plurality of control inductors 24 ′ (i.e.
- Control inductors 24 ′ are connected to a variable DC current source and control system in this example, represented by 50 , as will be described further below. Therefore, one can see that primary winding 22 , control winding 24 and control flux bus 32 co-operate in the present invention to provide an saturable core inductor on-board the stator 12 .
- Saturable core inductors are known to be useful in the regulation of AC power, and in one aspect the present invention provides an integrated approach to implementing a regulation scheme of this generic type, as will be further described.
- rotor 12 in use, in a alternator mode rotor 12 is moved relative to stator 20 , and the interaction of magnets 14 and power windings 22 creates a primary magnetic flux within PM machine 10 along a primary magnetic flux path or magnetic circuit 60 .
- the primary flux induces a voltage in the power winding, which when an electrical load is connected results in an induced current, and the induced current causes a secondary magnetic flux to circulate an adjacent secondary magnetic flux path or magnetic circuit 62 .
- the primary and secondary circuits are thus magnetically coupled when a current flows in the power winding.
- the secondary magnetic circuit 62 is for the most part isolated from the rotor and primary magnetic circuit 60 .
- Primary magnetic circuit 60 includes rotor 12 , rotor air gap 34 , power flux bus 36 and the portion of stator teeth 30 between rotor 12 and power flux bus 36 .
- Primary magnetic circuit encircles a portion of power winding 22 and, in use as an alternator causes a current flow in power winding 22 .
- Secondary magnetic circuit 62 includes power flux bus 36 , control bus 32 and the portion of stator teeth 30 between control bus 32 and power flux bus 36 . In this embodiment, secondary magnetic circuit encircles the portions of the power winding 22 and control winding 24 in slot 28 b .
- Power flux bus 36 divides slot 28 into two slot portions or openings 28 a and 28 b , with one opening 28 a for the power winding only, and another opening 28 b for the power and control windings.
- the primary magnetic circuit encircles an opening 28 a while the secondary magnetic circuit encircles an opening 28 b .
- Opening 28 a is preferably radially closer to the rotor than opening 28 b .
- Power flux bus 36 is preferably common to both the primary and secondary magnetic circuit paths and thus the primary and secondary magnetic circuits are magnetically coupled, as mentioned.
- a tertiary magnetic circuit 64 preferably circulates around control bus 32 , as partially indicated in FIG. 2 (i.e. only a portion of the tertiary circuit is shown, as in this embodiment the tertiary circuit circulates the entire stator).
- the control flux bus 32 is preferably common to both the secondary and tertiary magnetic circuit paths and thus the secondary and tertiary magnetic circuits are also magnetically coupled. As mentioned, at least a portion of control flux bus 32 is saturable.
- the present invention When operated as an alternator, the present invention permits the output of the power winding(s) 22 to be controlled through a manipulation of current supplied to control winding(s) 24 , as will now be described.
- the equivalent power inductor 22 ′ is formed by the portion of the power winding 22 in slot 28 b and the secondary magnetic circuit 62 , as schematically represented by the equivalent circuit of FIG. 3 .
- the control winding 24 shares the secondary magnetic circuit, however since it is preferably wound in the same direction as the power winding 22 in each slot, as mentioned above, the effect achieved is similar to that provided by alternatingly reversed saturable inductors, and there is preferably substantially no net voltage generated within the control winding 24 by flux in the secondary magnetic circuit.
- control winding pattern relative to the power winding preferably results in a near net zero voltage induced in the control winding, which simplifies control. Also, since the DC control current through both control flux buses 34 produces magnetic fluxes in different directions relative to the power winding 22 , one bus 34 will saturate more in one cycle of the AC power while the other bus 34 will saturate more in the other, thus tending to equalize the control action through each half-cycle.
- the portion of the control flux bus 32 in which the flux directions are instantaneously opposing will become less saturated, which causes a proportional increase in the inductance. This effect tends to cause the output current to remain somewhat constant.
- the present invention causes the power output current of the alternator to become a function of the control current.
- the maximum inductance of the equivalent power inductor 22 ′ formed by the secondary magnetic circuit is related to the physical dimensions of the portions carrying the secondary magnetic circuit.
- control winding 24 may be used as a source of control of PM machine 10 .
- Means for controlling the operation of PM machine are thus available within the machine itself, as the “control” current may be generated by the PM machine 10 power windings, typically in conjunction with rectifiers. In some instances, therefore, no external source of control current may be required in conjunction with an electronic current control, although arranging the control winding in series with the rectified output current may also be used to control current to some extent.
- the novel architecture of the present invention therefore lends itself to many novel possibilities for control systems for the machine, a few examples of which will now described.
- the output (i.e. from a power winding 22 ) of alternator 10 may be controlled by connecting control winding 24 to a power supply 50 , and a current applied to the control winding preferably sufficient to fully saturate the control flux bus 32 , such saturation being caused by magnetic flux flowing along tertiary path 64 induced by current passing though control winding 24 , which is wrapped around control flux bus 32 in this embodiment.
- a current applied to the control winding preferably sufficient to fully saturate the control flux bus 32 , such saturation being caused by magnetic flux flowing along tertiary path 64 induced by current passing though control winding 24 , which is wrapped around control flux bus 32 in this embodiment.
- the current level provided by controlled current source supply 50 can be continuously varied, as required, to regulate the output current of the power windings (and thus, ultimately, output voltage) over a range of rotor speeds and electrical loads.
- a feedback control circuit is used by the control system of source 50 to compare the alternator output voltage (i.e. the output of power winding 22 ) to a fixed reference (e.g. representative of a desired output voltage level(s)), and control can be configured such that, when the alternator output voltage is less than a desired reference level, a command is provided to increase the control current to increase saturation level and therefore output current, and thus voltage.
- a command is similarly provided to reduce the control current to decrease saturation level and therefore output current, which ultimately permits output voltage control as well. In this way, the output voltage of the alternator can be regulated.
- the output of power winding 22 is reduced and may be, by design, limited by the construction of the machine such that the machine's impedance is sufficient to limit short circuit currents to that which the machine may comfortably handle without damage (i.e. the short circuit current is low enough that it would not, for example, pose a danger such a machine overheating, etc.).
- the present invention operates in a similar manner reminiscent of the “fusible-secondary” embodiment of the applicants co-pending US patent application referred to and incorporated above.
- control current i.e. the current in control windings 24
- modulation of the control current i.e. the current in control windings 24
- a rapidly varying current so as to cause cyclic amplitude modulation of the alternator output, thereby resulting in the generation of new output frequencies (or side bands) which are different from the raw frequency of the machine (i.e. speed times pole pair frequency of the alternator).
- Magnetic flux preferably circulates the tertiary magnetic circuit 64 in the same direction around the control flux bus 32 .
- the control winding is provided in the slots corresponding to a particular phase of the three-phase machine described, the power windings are wound in the opposite direction in each slot which is due to the opposite polar arrangement of the magnets 14 associated with each adjacent slot of the phase.
- the control windings are preferably wound in the same direction in all slots.
- a net-zero voltage is induced in control windings 24 , which is desirable because a relatively low DC potential is required to provide DC control currents, thus no special considerations are required to remove a significant AC potential on the control winding.
- the present invention also advantageously permits load to be shared between a plurality of alternators/generators.
- the control winding controls the output current of the machine.
- the output of the rectifiers can be directly connected together such to feed a common load circuit.
- Each alternator's contribution to the load current is set by control of the DC current (in this example) provided to each alternator from controlled source 50 ′.
- a control system integrated in 50 can sense this and provide a seamless sharing of load by increasing the current contribution of one or more of the remaining alternators to preferably make up the deficit from the failed or shut down alternator.
- both machines 10 can be integrated in to a single rotor-stator assembly.
- primary flux bus 36 may be provided with a low Curie point materials in accordance wit the applicant's co-pending application incorporated above, so as to provide thermal protection in the event that a fault causes normal operating temperatures to be exceeded.
- Control schemes such as those disclosed above may be employed individually or may be combined as desired to permit several control features to exist contemporaneously within the PM machine.
- prior art fixed-geometry PM machines typically are not controllable in any way other than by the speed at which they are operated, this controllability feature of the present invention is of significant value to the PM machine designer, particularly in those applications where the rotational speed of the machine cannot itself be used to control machine output.
- the present invention also offers a robust and reliable design suitable for aerospace applications. The power-sharing opportunities offered by the present invention also cannot be ignored.
- control winding 224 is provided in a separate closed slot 228 c adjacent to the closed slot portion 228 b .
- the secondary magnetic circuit 262 and tertiary magnetic circuit 264 share the control flux bus 232 .
- Reference numerals in FIG. 4 are similar to those of FIG. 2 , but incremented by two hundred.
- control flux bus may be saturated instead with a permanent magnet brought into close proximity to the control flux bus by an appropriate control and actuation system, which may be mechanical, electrical, electronic or otherwise, or combinations thereof.
- the present invention may also be used for electric motor control purposes.
- the present invention when used as a starter motor, the present invention may be used to vary the impedance of the motor and thereby control current transients experienced during motoring, the torque speed relationship can also be adjusted to some degree using the control winding, since the phase angle between the rotor mmf and the armature mmf are variable due to the variable inductance of the power winding.
- alternators/generators are possible for alternators/generators, as well.
- varying or modulating the saturation level appropriately may be used to control the frequency of output alternating current in the power windings by variably shifting the generated frequency, as the alternator speed is varied, so as to provide a desired constant output frequency.
- alternator output frequency consists of two or more frequency components (i.e. sum and difference frequencies or sidebands).
- Appropriate filtering, subtraction or detection of one of the frequencies will result in a new single output frequency which is related to the sum or difference between the alternator frequency and the control frequency.
- Active rectification of the envelope of a modulated alternator output could also be used to provide a new power frequency.
- the machine may be single or multi-phase, single or multichannel.
- the windings may have single or multiple turns per slot, the number of turns of a winding not necessarily have to be a whole number, the number of power windings does not have to equal the number of control windings, and one or more windings may perhaps be present in a slot.
- the windings may be any conductor(s) (i.e. single conductor, more than one wire, insulated, laminated. Litz etc.) or may be superconductors.
- the rotor can be any electromagnetic configuration suitable (i.e. permanent magnet rotor not necessary), and may be provided in an outside or inside configuration, or any other suitable configuration. Other winding configurations are possible, and the ones described above need not be used at all, or throughout the apparatus. Also, the magnetic circuits described can be arranged in the stator (and/or rotor) in any suitable manner. Likewise, the stator and rotor may also have any suitable configuration. Any suitable saturation means may be used. Although a DC source is preferred for control of saturation in some embodiments described above, an AC source may also be used in certain circumstances to achieve desired results, as the skilled reader will understand.
Abstract
Description
- The applicant's co-pending U.S. patent application Ser. No. 10/444,952 is hereby incorporated by reference. The invention, however, is not necessarily limited to such architecture, as will become apparent to the skilled reader in light of the teachings herein.
- The invention relates to electric machines such as alternators and motors, and in particular to the control of such machines.
- Referring to
FIG. 1 , a typical permanent magnet (PM) alternator or motor has arotor 102 supportingpermanent magnets 104 and mounted on arotatable shaft 108. Astator 110 has a plurality ofwindings 112 between a plurality ofteeth 114 mounted to aback iron 116. (For ease of illustration, the adjacent elements ofwindings 112 inFIG. 1 are shown unconnected.) When operated in an alternator mode, an external torque source forces rotation of the shaft, and the interaction of the magnets and the windings causes a magnetic flux to loop the windings in the slots. As magnetic flux varies due to rotor rotation, voltage is generated inwindings 112, which results in an output current when a load is connected to the output of the machine. When operated in a motor mode, voltage from an external source (not shown) is applied towindings 112, and the resulting current induces magnetic flux in the stator and rotor which, when appropriately controlled, causes the rotor to rotate to produce torque. PM machines can have an “inside rotor” configuration as shown InFIG. 1 , or an “outside rotor” configuration (not shown). - The output voltage and frequency of prior art PM alternators is determined by rotor speed, which present challenges where rotor speed cannot be independently controlled. It would therefore be desirable to improve the controllability of electric machines, generally, and in particular PM machines.
- In one aspect, the present invention provides an electric alternator/motor comprising: a rotor having a plurality of permanent magnets; a stator having a plurality first slots and a plurality of second slots, the first slots being located on a periphery of the stator opposing the rotor, the second slots being located on an opposite side of the first slots relative to the rotor; at least a first winding disposed in a plurality of said first and second slots; at least a first magnetic circuit defined in the stator and rotor which encircles at least one first slot in which the first winding is disposed; at least a second magnetic circuit encircling at least one of the second slots in which the first winding is disposed, the second magnetic circuit sharing a common portion of the stator with the first magnetic circuit, the second magnetic circuit including a magnetically saturable portion of the stator distinct from the common portion; at least a second winding disposed adjacent the first winding in a plurality of second slots; a third magnetic circuit defined in the stator and including the magnetically saturable portion of the stator, the third magnetic circuit operatively associated with current passing through the second winding; a current source connected to the second winding and adapted to pass a sufficient amount of said current through the second winding to substantially saturate said magnetically saturable portion of the stator; and a controller adapted to vary said current provided to the second winding to vary a saturation level of the magnetically saturable portion.
- In another aspect, the invention provides a machine operable as at least one of an electric alternator/generator and an electric motor, the machine comprising a rotor and stator assembly, the assembly having a stator including at least a first winding, the assembly also having first and second magnetic circuits and a saturation control assembly, the first magnetic circuit including the rotor and encircling at least a first portion of the first winding, the second magnetic circuit encircling at least a second portion of the first winding remote from the first magnetic circuit, the first and second magnetic circuits magnetically coupled when current flows in the first winding, the second magnetic circuit including a portion which is magnetically saturable, the saturation control assembly being operatively associated with the magnetically saturable portion of the second circuit and operable to controllably vary a saturation level of said saturable portion.
- In another aspect, the invention provides an electric alternator comprising: a magnetic rotor; a stator having a body and at least one power winding adapted to generate voltage and current at least partially in response to rotor movement relative to the stator, the stator further comprising at least one saturable core inductor assembly in series with the power winding, wherein a saturable core portion of the saturable core inductor assembly is intrinsically provided by the stator body; and a saturation control apparatus adapted to selectively control a saturation level of the saturable core portions.
- In another aspect, the invention provides an electric machine operable as at least one of an electric alternator/generator and an electric motor, the machine having a rotor and a stator, the stator including at least a first winding, the machine comprising: a first magnetic circuit which includes the rotor and encircles at least a first portion of the first winding; a second magnetic circuit which encircles at least a second portion of the first winding, the first and second magnetic circuits magnetically coupled when current flows in the first winding, the second magnetic circuit including a portion which is magnetically saturable; and means for controllably varying a saturation level of said saturable portion.
- In another aspect, the invention provides a method of regulating an electrical output connected to a load, the method involving at least one alternator connected to the load, the alternator having a magnetic rotor, a stator and at least one stator winding, the winding associated with a primary magnetic circuit including the rotor and a secondary magnetic circuit defined in the stator, the secondary magnetic circuit being magnetically coupled to the primary magnetic circuit and including a magnetically saturable portion, the method comprising the steps of moving the rotor relative to the stator to generate an output current in the winding, and controllably varying a saturation level of a portion of the secondary magnetic circuit.
- In another aspect, the invention provides a method of power sharing among such machines. Still other inventions are disclosed in this specification and attached figures, as well, and the present application claims all such inventions.
- For a better understanding of the present invention and to show more dearly how it may be carried into effect, reference will now be made by way of example to the accompanying drawings, showing articles made according to preferred embodiments of the present invention, in which:
-
FIG. 1 is a somewhat schematic cross-sectional view of a prior art permanent magnet alternator/motor; -
FIG. 2 is somewhat schematic partial cross-sectional view of a alternator/motor according to the present invention; -
FIG. 3 is a schematic of a partial equivalent circuit of the alternator/motor ofFIG. 2 , illustrating its functional aspects; -
FIG. 4 is similar toFIG. 2 , but depicting another embodiment of the invention; -
FIG. 5 is a block diagram schematically illustrating another aspect of the present invention; and -
FIG. 6 is a block diagram schematically illustrating another aspect of the present invention. - Referring to
FIG. 2 , a portion of a permanent magnet (PM) electric machine according to the present invention is depicted in at 10. For ease of illustration and description,FIG. 2 shows a linear arrangement of theelectric machine 10, however it is to be understood that the machine is generally preferred to have a circular architecture, with an inside or outside rotor. It will also be understood by the skilled reader thatFIG. 2 and the accompanying description are schematic in nature, and that many routine details of the design have been omitted for clarity. Themachine 10 may be configured as an alternator to generate electrical power, or motor to convert electrical power into mechanical torque, or both. The description below is directed to an electric machine operable as both and alternator and motor. - Alternator/
motor 10 has arotor 12 withpermanent magnets 14 which is mounted for rotation relative to a stator 20. Stator 20 has at least one power winding 22 and preferably at least one control winding 24, and this embodiment stator 20 has a 3-phase design with three electromagnetically-independent power windings 22 (the phases are denoted by thecircled numerals 1, 2, 3, respectively) and, correspondingly, threeindependent control windings 24. The power and control windings are separated in this embodiment by a winding air gap 26 and disposed inradial slots 28 between a plurality of adjacent teeth 30. (For ease of illustration inFIG. 2 , the adjacent elements of control winding 24 are shown unconnected. For ease of description, theadjacent slots 28 are indicated as A, B, C, D, etc.) Power winding 22 and control winding 24 are electrically isolated from one another. Aback iron 32, or control flux bus as it is described in this application, extends betweenslots 28. Arotor air gap 34 separatesrotor 12 and stator 20 in a typical fashion. A core or “bridge” portion or “power flux bus” 36 portion of stator also extends between adjacent pairs of teeth 30 between adjacent portions of power winding 22. - The materials for
PM machine 10 may be any deemed suitable by the designer. Materials preferred by the inventor are: samarium cobalt permanent magnets, copper power and control windings, a suitable saturable electromagnetic material for the stator teeth such as electrical silicon steels commonly used in the construction of magnetic machines, power and control flux busses. The stator teeth, power and control flux busses may be integral or non-integral with one another, as desired. The designer will select the rotor and stator dimensions and materials based at least in part on the desired properties of the magnetic circuits (described below) in the machine to yield the desired machine performance, etc. Thecontrol flux bus 32 is magnetically saturable, as will be described below. - Power winding 22 in this embodiment consists of a single conductor which enters
slot 28 on a first side ofpower flux bus 36, crossespower flux bus 36 at the other end andexits slot 28 on the second or other side of power flux bus 36 (i.e. opposite to the first side, or side of entry) and proceeds to anext slot 28 of the same phase, where the power winding 22 preferably enters this next slot from the second side ofpower flux bus 36 instead of the first side, as described above. The winding of power winding 22 is preferably similar to that described in the incorporated reference. - Meanwhile, control winding 24 is wrapped around the control flux bus, in this embodiment preferably multiple times, such as 25 times, for reasons described below. The direction of winding between adjacent appropriate slots (i.e. appropriate to maintain phase correspondence with the power winding) is preferably the same from slot to slot, and thus alternatingly opposite relative to the power winding 22, so that a net-zero voltage is induced in the control winding, as will also be described further below.
Control winding 24 is connected to a current source and control system 50 (seeFIG. 3 ), which in this example includes a variable current DC source and an appropriate solid state control system preferably having functionality as described further below. The current provided by such source is preferably sufficient to saturatecontrol bus 32, as will be described. - Referring to
FIG. 3 , alternator/motor 10 as just described can also be represented schematically by anequivalent circuit 10′ having a plurality of alternatingcurrent sources 12′ (i.e. each, equivalent to the moving magnetic rotor system in conjunction with the portion of a power winding 22 located inslot portions 28 a) connected to a plurality ofpower inductors 22′ (i.e. equivalent to the portion of theprimary winding 22 located in theslot portion 28 b), thecurrent sources 12′ andpower inductors 22′ arranged alternately in series. Associated withpower inductors 22′ are a plurality ofcontrol inductors 24′ (i.e. equivalent to control winding 24) havingsaturable cores 32′ (equivalent to the saturable control flux bus 32).Control inductors 24′ are connected to a variable DC current source and control system in this example, represented by 50, as will be described further below. Therefore, one can see thatprimary winding 22, control winding 24 andcontrol flux bus 32 co-operate in the present invention to provide an saturable core inductor on-board thestator 12. Saturable core inductors are known to be useful in the regulation of AC power, and in one aspect the present invention provides an integrated approach to implementing a regulation scheme of this generic type, as will be further described. - Referring again to
FIG. 2 , in use, in aalternator mode rotor 12 is moved relative to stator 20, and the interaction ofmagnets 14 andpower windings 22 creates a primary magnetic flux withinPM machine 10 along a primary magnetic flux path ormagnetic circuit 60. The primary flux induces a voltage in the power winding, which when an electrical load is connected results in an induced current, and the induced current causes a secondary magnetic flux to circulate an adjacent secondary magnetic flux path ormagnetic circuit 62. The primary and secondary circuits are thus magnetically coupled when a current flows in the power winding. The secondarymagnetic circuit 62 is for the most part isolated from the rotor and primarymagnetic circuit 60. (It is to be understood that this description applies only to phase “1” of the described embodiment, and that similar interactions, etc. occur in respect of the other phases). The skilled reader will appreciate in light of this disclosure that it may be desirable in many situations to include a regulation apparatus to maintain a minimum current in the power winding during no-load conditions. - Primary
magnetic circuit 60 includesrotor 12,rotor air gap 34,power flux bus 36 and the portion of stator teeth 30 betweenrotor 12 andpower flux bus 36. Primary magnetic circuit encircles a portion of power winding 22 and, in use as an alternator causes a current flow in power winding 22. Secondarymagnetic circuit 62 includespower flux bus 36,control bus 32 and the portion of stator teeth 30 betweencontrol bus 32 andpower flux bus 36. In this embodiment, secondary magnetic circuit encircles the portions of the power winding 22 and control winding 24 inslot 28 b.Power flux bus 36 dividesslot 28 into two slot portions oropenings opening 28 b for the power and control windings. The primary magnetic circuit encircles anopening 28 a while the secondary magnetic circuit encircles anopening 28 b.Opening 28 a is preferably radially closer to the rotor than opening 28 b.Power flux bus 36 is preferably common to both the primary and secondary magnetic circuit paths and thus the primary and secondary magnetic circuits are magnetically coupled, as mentioned. - A tertiary
magnetic circuit 64 preferably circulates aroundcontrol bus 32, as partially indicated inFIG. 2 (i.e. only a portion of the tertiary circuit is shown, as in this embodiment the tertiary circuit circulates the entire stator). Thecontrol flux bus 32 is preferably common to both the secondary and tertiary magnetic circuit paths and thus the secondary and tertiary magnetic circuits are also magnetically coupled. As mentioned, at least a portion ofcontrol flux bus 32 is saturable. - When operated as an alternator, the present invention permits the output of the power winding(s) 22 to be controlled through a manipulation of current supplied to control winding(s) 24, as will now be described.
- As explained above, the
equivalent power inductor 22′ is formed by the portion of the power winding 22 inslot 28 b and the secondarymagnetic circuit 62, as schematically represented by the equivalent circuit ofFIG. 3 . The control winding 24 shares the secondary magnetic circuit, however since it is preferably wound in the same direction as the power winding 22 in each slot, as mentioned above, the effect achieved is similar to that provided by alternatingly reversed saturable inductors, and there is preferably substantially no net voltage generated within the control winding 24 by flux in the secondary magnetic circuit. - The application of a DC current from the
source 50 to the control winding 24 results in a DCflux circulating circuit 64 in thecontrol flux bus 32. At the instant in time depicted inFIG. 2 , it can be seen that the DC flux in tertiarymagnetic circuit 64 in thecontrol flux bus 32 is in the same direction in slot A as the AC flux in secondarymagnetic circuit 62, but in slot D the direction of the DC flux in tertiarymagnetic circuit 64 in thecontrol flux bus 32 is opposite to the AC flux in secondarymagnetic circuit 62. As the DC current is increased in the control winding 24, the flux density in thecontrol bus 32 is increased such that the saturation flux density is eventually reached. It will be understood that saturation is reached first in the regions in the control bus where the AC flux and the DC flux are in the same direction, and that at higher DC control currents both regions of the control bus become saturated regardless of flux direction. Once saturation occurs, the AC flux in the secondary magnetic circuit due to the current in the power winding, is very significantly reduced. - As mentioned, the control winding pattern relative to the power winding preferably results in a near net zero voltage induced in the control winding, which simplifies control. Also, since the DC control current through both
control flux buses 34 produces magnetic fluxes in different directions relative to the power winding 22, onebus 34 will saturate more in one cycle of the AC power while theother bus 34 will saturate more in the other, thus tending to equalize the control action through each half-cycle. - Once saturated, magnetic materials substantially lose their ability to conduct magnetic flux, and as such appear to be non-magnetic to both AC magnetic forces (HAC) and further changes in DC magnetic influence (HDC). The net effect of this saturated condition in the
control bus 32 is thus to virtually eliminate the inductance due to the secondary magnetic circuit, which thereby significantly reduces inductance of the machine. - Furthermore, as the current flow in the power winding 22 increases, for example due to an increase in the external load or an increase in the generated output voltage due to an increase in operating speed, the portion of the
control flux bus 32 in which the flux directions are instantaneously opposing will become less saturated, which causes a proportional increase in the inductance. This effect tends to cause the output current to remain somewhat constant. Thus the present invention causes the power output current of the alternator to become a function of the control current. The maximum inductance of theequivalent power inductor 22′ formed by the secondary magnetic circuit is related to the physical dimensions of the portions carrying the secondary magnetic circuit. The power winding short circuit current is related to the ampere-turns in the control winding by:
IP*Np+K=IC*Nc
where: Np and Nc are the number of turns in the power and control windings, respectively, IP and IC are the currents in the power and control windings, respectively, and K is a constant which is inversely proportional to the maximum inductance of the power winding and other machine design features. - This permits manipulation of the output of power winding 22, and thus control winding 24 may be used as a source of control of
PM machine 10. Means for controlling the operation of PM machine are thus available within the machine itself, as the “control” current may be generated by thePM machine 10 power windings, typically in conjunction with rectifiers. In some instances, therefore, no external source of control current may be required in conjunction with an electronic current control, although arranging the control winding in series with the rectified output current may also be used to control current to some extent. The novel architecture of the present invention therefore lends itself to many novel possibilities for control systems for the machine, a few examples of which will now described. - For example, the output (i.e. from a power winding 22) of
alternator 10 may be controlled by connecting control winding 24 to apower supply 50, and a current applied to the control winding preferably sufficient to fully saturate thecontrol flux bus 32, such saturation being caused by magnetic flux flowing alongtertiary path 64 induced by current passing though control winding 24, which is wrapped aroundcontrol flux bus 32 in this embodiment. When saturation occurs, flux around the secondarymagnetic circuit 62 is effectively eliminated, and the magnetic relationship between the power windings and the secondary magnetic circuit is such that inductance in the power winding is virtually eliminated. Thus, more current is permitted to flow in the power winding. Therefore, the current level provided by controlledcurrent source supply 50 can be continuously varied, as required, to regulate the output current of the power windings (and thus, ultimately, output voltage) over a range of rotor speeds and electrical loads. In order to effect constant output voltage control, for example, a feedback control circuit is used by the control system ofsource 50 to compare the alternator output voltage (i.e. the output of power winding 22) to a fixed reference (e.g. representative of a desired output voltage level(s)), and control can be configured such that, when the alternator output voltage is less than a desired reference level, a command is provided to increase the control current to increase saturation level and therefore output current, and thus voltage. Likewise, when the alternator output voltage is above a desired reference value (which may or may not be the same reference value mentioned above), a command is similarly provided to reduce the control current to decrease saturation level and therefore output current, which ultimately permits output voltage control as well. In this way, the output voltage of the alternator can be regulated. - In another control method, if no current is supplied to control winding 24, the output of power winding 22 is reduced and may be, by design, limited by the construction of the machine such that the machine's impedance is sufficient to limit short circuit currents to that which the machine may comfortably handle without damage (i.e. the short circuit current is low enough that it would not, for example, pose a danger such a machine overheating, etc.). In this respect, the present invention operates in a similar manner reminiscent of the “fusible-secondary” embodiment of the applicants co-pending US patent application referred to and incorporated above.
- Many other control schemes are also possible, including the modulation of the control current (i.e. the current in control windings 24) control with a rapidly varying current so as to cause cyclic amplitude modulation of the alternator output, thereby resulting in the generation of new output frequencies (or side bands) which are different from the raw frequency of the machine (i.e. speed times pole pair frequency of the alternator).
- Magnetic flux preferably circulates the tertiary
magnetic circuit 64 in the same direction around thecontrol flux bus 32. As mentioned above, although the control winding is provided in the slots corresponding to a particular phase of the three-phase machine described, the power windings are wound in the opposite direction in each slot which is due to the opposite polar arrangement of themagnets 14 associated with each adjacent slot of the phase. To ensure that a uniform direction for the tertiarymagnetic circuit 64 is provided, as mentioned the control windings are preferably wound in the same direction in all slots. Also as mentioned, a net-zero voltage is induced incontrol windings 24, which is desirable because a relatively low DC potential is required to provide DC control currents, thus no special considerations are required to remove a significant AC potential on the control winding. - The present invention also advantageously permits load to be shared between a plurality of alternators/generators. The control winding controls the output current of the machine. Thus, referring to
FIG. 5 , ifseveral alternators 10 are connected tosimple rectifiers 60, the output of the rectifiers can be directly connected together such to feed a common load circuit. Each alternator's contribution to the load current is set by control of the DC current (in this example) provided to each alternator from controlledsource 50′. In this way, if a single alternator should fail or be shut down, a control system integrated in 50 can sense this and provide a seamless sharing of load by increasing the current contribution of one or more of the remaining alternators to preferably make up the deficit from the failed or shut down alternator. - It is also possible with this invention to connect properly phased
alternators 10 directly together such that the AC output of a plurality ofalternators 10 having matched phases (e.g. phase “1”, as described above) can be parallely connected, as shown inFIG. 6 . Current sharing control is provided throughcontrol system 50″ which also adjusts the control current in each alternator as described above. This can lead to certain advantages of mechanical arrangements when the maximum diameter or shaft length of a single machine must be maintained below a particular value for, say, rotor dynamic or other reasons. In this way, twosmaller machines 10 on asingle shaft 70, for example, can provided a sufficiently large power output to a larger shared common load circuit - In both of the above examples, this permits a much simpler means by which power may be shared, and does not require the complicated control systems of the prior art. This feature may be used advantageously, as well, in a “dual channel” electric machine, as described in the applicant's co-pending patent application incorporated above. Referring again to
FIGS. 5 and 6 , for example bothmachines 10 can be integrated in to a single rotor-stator assembly. - in another embodiment, as discussed above,
primary flux bus 36 may be provided with a low Curie point materials in accordance wit the applicant's co-pending application incorporated above, so as to provide thermal protection in the event that a fault causes normal operating temperatures to be exceeded. - Control schemes such as those disclosed above may be employed individually or may be combined as desired to permit several control features to exist contemporaneously within the PM machine. As prior art fixed-geometry PM machines typically are not controllable in any way other than by the speed at which they are operated, this controllability feature of the present invention is of significant value to the PM machine designer, particularly in those applications where the rotational speed of the machine cannot itself be used to control machine output. The present invention also offers a robust and reliable design suitable for aerospace applications. The power-sharing opportunities offered by the present invention also cannot be ignored.
- In another embodiment, shown in
FIG. 4 , the control winding 224 is provided in a separateclosed slot 228 c adjacent to theclosed slot portion 228 b. The secondarymagnetic circuit 262 and tertiarymagnetic circuit 264 share thecontrol flux bus 232. Reference numerals inFIG. 4 are similar to those ofFIG. 2 , but incremented by two hundred. - In another embodiment, not depicted, rather than rely on a control winding 24 and controlled
current source 50 for saturation control, the control flux bus may be saturated instead with a permanent magnet brought into close proximity to the control flux bus by an appropriate control and actuation system, which may be mechanical, electrical, electronic or otherwise, or combinations thereof. - The present invention may also be used for electric motor control purposes. For example, when used as a starter motor, the present invention may be used to vary the impedance of the motor and thereby control current transients experienced during motoring, the torque speed relationship can also be adjusted to some degree using the control winding, since the phase angle between the rotor mmf and the armature mmf are variable due to the variable inductance of the power winding. Similarly, other modes of control are possible for alternators/generators, as well. For example, as briefly mentioned above, varying or modulating the saturation level appropriately may be used to control the frequency of output alternating current in the power windings by variably shifting the generated frequency, as the alternator speed is varied, so as to provide a desired constant output frequency. This may be done using amplitude modulation techniques such that the alternator output frequency consists of two or more frequency components (i.e. sum and difference frequencies or sidebands). Appropriate filtering, subtraction or detection of one of the frequencies will result in a new single output frequency which is related to the sum or difference between the alternator frequency and the control frequency. Active rectification of the envelope of a modulated alternator output could also be used to provide a new power frequency.
- The above description is therefore meant to be exemplary only, and one skilled in the art will recognize that other changes may also be made to the embodiments described without departing from the scope of the invention disclosed. For example, the machine may be single or multi-phase, single or multichannel. The windings may have single or multiple turns per slot, the number of turns of a winding not necessarily have to be a whole number, the number of power windings does not have to equal the number of control windings, and one or more windings may perhaps be present in a slot. The windings may be any conductor(s) (i.e. single conductor, more than one wire, insulated, laminated. Litz etc.) or may be superconductors. In multiphase machines, there may be delta or Y-connected windings in accordance with known techniques. There need not be an air gap between the power and control winding, as long as the windings are electrically isolated from one another. The rotor can be any electromagnetic configuration suitable (i.e. permanent magnet rotor not necessary), and may be provided in an outside or inside configuration, or any other suitable configuration. Other winding configurations are possible, and the ones described above need not be used at all, or throughout the apparatus. Also, the magnetic circuits described can be arranged in the stator (and/or rotor) in any suitable manner. Likewise, the stator and rotor may also have any suitable configuration. Any suitable saturation means may be used. Although a DC source is preferred for control of saturation in some embodiments described above, an AC source may also be used in certain circumstances to achieve desired results, as the skilled reader will understand.
- Still other modifications which fall within the scope of the present invention will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the equivalents accorded to the appended claims. In this application, it is to be understood that the term ‘alternator’ is used sometimes used generically to mean a device used for generating electricity, and is not always intended therefore to be limited to a device for generating an output alternating current.
Claims (16)
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
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US10/996,411 US7262539B2 (en) | 2004-11-26 | 2004-11-26 | Saturation control of electric machine |
MX2007006305A MX2007006305A (en) | 2004-11-26 | 2005-10-28 | Saturation control of electric machine. |
PCT/CA2005/001657 WO2006056040A1 (en) | 2004-11-26 | 2005-10-28 | Saturation control of electric machine |
EP05802138.7A EP1829187B1 (en) | 2004-11-26 | 2005-10-28 | Saturation control of electric machine |
JP2007541595A JP5065902B2 (en) | 2004-11-26 | 2005-10-28 | Electric machine saturation control |
CN2005800472586A CN101111982B (en) | 2004-11-26 | 2005-10-28 | Electric machine |
CA2586424A CA2586424C (en) | 2004-11-26 | 2005-10-28 | Saturation control of electric machine |
RU2007123789/09A RU2346374C1 (en) | 2004-11-26 | 2005-10-28 | Electric motor-alternating voltage generator (versions) and alternating voltage generator (versions) |
BRPI0517907-6A BRPI0517907A (en) | 2004-11-26 | 2005-10-28 | alternator / electric motor, alternator / motor, and alternator |
US11/420,614 US7545056B2 (en) | 2003-05-27 | 2006-05-26 | Saturation control of electric machine |
US12/422,449 US7999431B2 (en) | 2003-05-27 | 2009-04-13 | Saturation control of electric machine |
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Application Number | Priority Date | Filing Date | Title |
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US10/996,411 US7262539B2 (en) | 2004-11-26 | 2004-11-26 | Saturation control of electric machine |
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US11/420,614 Continuation-In-Part US7545056B2 (en) | 2003-05-27 | 2006-05-26 | Saturation control of electric machine |
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EP (1) | EP1829187B1 (en) |
JP (1) | JP5065902B2 (en) |
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Also Published As
Publication number | Publication date |
---|---|
CN101111982A (en) | 2008-01-23 |
CA2586424A1 (en) | 2006-06-01 |
CN101111982B (en) | 2010-10-13 |
WO2006056040A1 (en) | 2006-06-01 |
JP2008522565A (en) | 2008-06-26 |
US7262539B2 (en) | 2007-08-28 |
EP1829187A4 (en) | 2010-10-06 |
EP1829187B1 (en) | 2020-01-15 |
BRPI0517907A (en) | 2008-10-21 |
RU2346374C1 (en) | 2009-02-10 |
JP5065902B2 (en) | 2012-11-07 |
MX2007006305A (en) | 2007-11-21 |
CA2586424C (en) | 2016-09-13 |
EP1829187A1 (en) | 2007-09-05 |
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